METHOD STATEMENT FOR PRE-CAST

PRE-STRESSED GIRDER CASTING

450

1600

35

500 600
500

1200

OBJECTIVE:
This method statement is submitted to address the procedure intended for the Casting of
Pre-stressed Girder.

PREPATORY WORKS
On a well compacted and leveled ground concrete bed shall be prepared. Top level and
straightness of formwork will be checked by surveyor.
Extreme care will be taken to produce smooth surface. Formwork will be fixed in such a
manner that concrete pad will be at same level throughout the length.
FORMWORK
FORMWORK CALCULATION

Load on Formwork
Areaof I −Girder=( 450 ×200 ) + ( 180 ×1100 ) +2 ( 0.5 ×135 ×150 )+2 ( 0.5 ×200 × 210 ) + ( 600 ×300 )

Areaof I −Girder=90000+ 198000+20255+ 42000+180000

2 2
Areaof I −Girder=530255 m m ≅ 0.5303 m

Volume of Concrete (I −Girder)=1.2× 0.5303

1
3 3
Volume of Concrete (I −Girder)=0.63636 mᶾ

Wet Volume of Concrete (I −Girder)=0.95454 mᶾ 2

Unit Weight of RCC Concrete=2500 kg /mᶾ

Weight of Concrete=2500× 0.95454

Weight of Concrete=2386.35 Kg ≅ 2.4 Ton

4 5 4
Dia of Mild Steel ¯¿ 0.75∈¿

0.75
Areaof Mild ¯¿ π ( )²
2

Areaof Mild ¯¿ 0.442∈ ²

Bearing Strengthof Each Mild ¯¿ 40000 psi

Load Carrying Capacity of Each Mild ¯¿ 40000× 0.442

Load Carrying Capacity of Each Mild ¯¿ 17673 lbs ≅ 8 Ton

Load Carrying Capacity of Each Mild ¯¿ Weight of Concrete

Formwork Safe
 13.2575KN/m

Deflection in Formwork
Wunit Weight of RCC Concrete=25 KN /mᶾ
0.35m
Areaof Girder=0.5303 m ²
0.203
UDL on Plate=25 × 0.5303=13.2575 KN /m

wl ² (13.2575)(0.35)²
Maximum Bending Moment= = =0.203
8 8 0.175

1 2 0.0237KN
Load at End Points= × ×0.35 × 0.203=0.02368
2 3 0.203

δ=0.0237 ( 0.352 )−( 12 × 23 × 0.35 ×0.203)× 38 × 0.175 δ

1.05
δ=0.004025 × × 0.02368 3
16 0.0237KN8
× 0.175

δ=0.004025−0.001554

δ=0.002471 m

δ=2.471 mm<3 mm

Safe in Deflection

FORMWORK ERECTION
Formwork will consist of steel plates. The steel plates will be fixed in true plumb and lines
as per design and approved drawings or as directed by the Engineer.
Prior to erection of steel plates shuttering oil to be applied on it.
The properly secured and sealed formwork will be erected, (Foam/rubber strips to be
used for Joint sealing) and through bolts will be provided. One side shutter shall be
opened after cable profile and shall be closed after checking steel and cable profile. Forms
alignment/Plumb shall be checked by consultant before concrete pouring.
A working platform adjacent to Girder shuttering shall be prepared with safe access to it.

Fixing of Steel Reinforcement

Before fixing steel, the area will be cleaned and all the dust, plastic waste, oil, remains of
concrete chipped off or placed shortly and debris will be removed.
Two coats of emulsion / polythene sheet 2mm will be applied at concrete pad surface
before fixing of reinforcement.
The bending and cutting of the steel will be done on site. The steel ready for fixing will be
categorized as per bar bending schedule

PRE STRESSING HARDWARES

After fixing of reinforcement trumpet cones will be installed at designated place as per
drawings in end stopper shuttering plates and sheath pipe will be inserted and fixed as per
given cable profile data accurately. Sheath pipe joints will be properly sealed with proper
overlap wrapped with plastic tape so as to prevent any leakage of concrete slurry into
sheath pipe.
Proper spacer blocks made of the same strength of concrete will be placed on all faces of
the structure.
Cable duct shall be supported rigidly at 1m c/c by using appropriate “U” bar tied with
girder reinforcement.
Extreme care will be taken during fixing of cable profile pipe so that there is no horizontal
or vertical movement possible for pipes during fixing of formwork and pouring of concrete
of Pre-stressed girder.

CASTING OF CONCRETE
Concrete pouring will be done by concrete pump or Crane and bucket and shall be used as
an alternate. Concrete will be vibrated with vibrators to ensure proper compaction and
prevent segregation and other undesirable defects due to improper placing.
Concrete will be placed in continuous approximately horizontal layers each of which will
be properly compacted. Wooden hammer shall be used for tamping as required.
Each deposit of concrete will be vibrated completely before another deposit of concrete is
placed over it.
All concrete will be consolidated with electric or pneumatic, power driven immersion and
external vibrators, as required. Additional layers of concrete will not be placed until the
layer previously placed has been worked thoroughly as specified.
Slump shall not exceed as recommend in approved mix designs.
The temperature of concrete when it is being placed will be not more than specified
limits.
Concrete Cylinder shall be prepared by lab technician as specified in specifications.
Top surface of Girder shall be finished properly and roughened to an amplitude of 6mm
with bunch of wire.
After concrete poured successfully, standard measure will be taken to avoid expulsion of
water from the green concrete. It will be covered with polythene sheet to protect it from
rain water and sunlight.

CURING OF CONCRETE
After removal of formwork standard methods will be adopted for the curing of the
concrete.
In case of water curing The girder will be cured by wrapping it with Hessian Cloth and
sprinkling water frequently or by applying approved curing compound or as directed by
the Engineer.